0337024 JOHNSON MEGAPHONE

Operator Information
* What happened, and when?* Under what conditions? Was the engine rpm high or low?Was the engine under load?* Are there any customer or dealer installed systems that could cause this symptom?* What else occurred?* When did the symptoms begin (and what else happened at that time)?Logged Diagnostic Codes
* Do they correlate to probable causes?* Did they occur at the same time as the symptoms?* Are some codes logged repeatedly?Other Symptoms
* Are they related to this symptom?* Do they have common probable causes?Finally, test each probable cause using the tests suggested by the procedure. Be sure to check electrical connectors and wires, especially on intermittent problems! Refer to P-501: Inspecting Electrical Connectors in Section 5 for details.P-301: Engine Will Not Crank
Probable root causes:* Battery cables/batteries* Starting motor solenoid or circuit problem (in system wiring)* Starting motor/flywheel ring gear* Transmission problem* Engine accessory* Hydraulic cylinder lock* Internal engine problem Perform the following tests in order:1. Check main disconnect switch, battery posts and battery/starter cables for loose connections and corrosion. Remove and clean cables and connections if corroded. Load test batteries. Refer to Special Instruction, SEHS9249 Use Of 4C4911 Battery Load Tester. If necessary, charge the batteries. Refer to Special Instruction, SEHS7633 Battery Test Procedure.2. Test starting motor solenoid operation. Check system wiring to starting motor solenoid. Refer to Systems Operation, Testing & Adjusting Manual.3. Test starting motor operation. Refer to Systems Operation, Testing & Adjusting Manual. Inspect starting motor pinion and ring gear for damage.4. Ensure free movement of driveline. If not free, refer to the Machine Systems Operation, Testing & Adjusting Manual.5. Verify timing pin was not left in the flywheel housing after setting valve lash. Use the 9S9082 Engine Turning Tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine accessories that can lock up the engine (power steering pump, oil pump, etc). Repair or replace as necessary. Refer to the Engine System Operation Testing & Adjusting and Disassembly & Assembly Manuals.6. Remove injectors and check for fluid in the cylinders. Refer to the Disassembly & Assembly Manual.7. Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment, etc. Refer to the Disassembly & Assembly Manual.P-302: Engine Cranks But Will Not Start
Probable root causes:* Low fuel* Machine/engine wiring* Personality Module or ECM* Speed/Timing Signal; injection timing, incorrect speed/timing gear orientation assembly, Speed/Timing Sensor Calibration Error after replacement.* Electrical connections to the unit injector solenoids* Fuel supply: poor fuel quality or unit injector priming problem, low supply pressure, air in low pressure fuel supply circuit* Combustion problem Perform the following tests in order:1. Visually check fuel level (do not rely on fuel gauge only).2. Check for correct installation of the ECM Connectors J1/P1 and J2/P2, Speed/Timing Sensor Connector J20/P20, and Unit Injector Connector J91/P91. Refer to P-501: Inspecting Electrical Connectors. If the problem occurs only after the engine is warmed up, the circuit breakers may be exceeding the trip point because of overheating. Check the circuit breakers on the machine. Reset if required.3. Verify there is not an Active 253-02 Diagnostic Code. If the diagnostic code is present, refer to Programming Parameters in Section 2.4. Observe engine rpm on an Electronic Service Tool Status Screen while cranking the engine. If the Electronic Service Tool displays 0 rpm while cranking the engine, there is a problem in the Speed/Timing Sensor Circuit. Refer to P-514: Speed/Timing Sensor. If engine rpm is present (50 rpm or more while cranking) the Speed/Timing Circuit appears to be operating correctly. Verify that the timing reference gear is installed correctly and keyed to the camshaft by means of the locating dowel. If the gear was installed backwards or flipped over during assembly, the engine will not start. Check for proper orientation between crankshaft and camshaft drive gears. Repair as required. Refer to procedure in Disassembly & Assembly Manual.5. Make sure the unit injector connectors are properly installed. Refer to P-515: Injector Solenoids and perform the Injector Solenoid Test as a quick check to confirm that the ECM can energize the unit injector solenoids.6. Monitor exhaust for smoke while cranking. If smoke is not present there may be a fuel supply problem.7. Check for restricted, collapsed, or pinched fuel lines and repair or replace as required. Refer to the Systems Operation, Testing & Adjusting Manual.8. Check fuel tank for foreign objects which may block the fuel supply.9. Check for air in the low pressure fuel supply system after replacing filter, working on the low pressure fuel supply circuit, or replacing unit injectors. Purge air from the low pressure fuel supply circuit with the hand priming pump and cranking the engine in 30 second cycles, pausing at least two minutes between cranking cycles to allow the starting motor to cool. Loosen low pressure fuel line fitting on inlet to pressure regulating valve and hand prime again if air in fuel continues. A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel.10. Check fuel quality. In temperatures below 0°C (32°F), check for congealed fuel (wax). Refer to SEBD0717, Diesel Fuels And Your Engine.11. Check fuel pressure after the filter in the supply circuit during cranking. Refer to the Systems Operation, Testing & Adjusting Manual for correct pressure values. If pressure is low, check for plugged fuel filter. If pressure is still low, repair or replace fuel transfer pump, fuel transfer pump coupling, and fuel pressure regulating valve as needed.12. Check for combustion problems.P-303: Engine Misfires, Runs Rough Or Is Unstable
If the problem is intermittent and cannot be recreated, refer to P-306: Intermittent Low Power Or Power Cutouts. If the problem is consistent and can be recreated, continue with this procedure. Probable root causes:* Cold Mode Operation (Normal Operation, if the problem occurs only after start-up)* Throttle Switch Signal* Faulty electronic unit injector circuit (individual cylinder malfunction)* Fuel supply: low supply pressure, air in low pressure fuel supply circuit, poor fuel quality* Air